Method of molding duplicate sound-records and other objects.



- J. W. AYLSWORTH. METHOD OF MOLDING DUPLICATE SOUND RECORDS AND OTHEROBJECTS.

' APPLICATION FILED MAYI, 1909. I

1 1%,859 Patented July 13, 1915.

E sraTEsraTaNT orrica.

JoNAs w. AYLswonTH, or EAsT 0RANG-E, NEW JERSEY, ASSIGNOR To NEw JERSEYPATENT COMPANY, OF wEsT ORANGE, NE JERSEY, A CORPORATION OF NEW JERSEY.

METHOD OF MOLDING DUPLICATE SOUND-RECORDS AND OTHER OBJECTS.

Specification of Letters Patent. I Patented July 13, 19115.

Application filed May 1, 1909. Serie1No.493,416.

To all whom it may concern:

Be it known that I, J ONAS W. AYLswoRTH, a citizen of the United Statesanda resident of East Orange, in the county of Essex and State of NewJersey, have made a certain new and useful Invention in Methods ofxMold-i ng Duplicate Sound-Records and other Objects, of which thefollowmg is a I am enabled to mold sound records, both cylindrical anddisk, from such bodies as are produced when albumenoids and caseins arecombined with formaldehyde or other aldehydes or equivalent substances,and ,the various non-plastic condensation products of phenols, theirhomologue's, their polymers and derivatives. These bodies have notheretofore been successfully molded into sound records, but are adaptedto form excellent sound records if successfully molded, because of theirphysical qualities, which are especially useful for the pu'pose.Heretofore, sound records or other objects could only be molded fromsuch substances by molding the material in the earlier plastic stages ofits formation and completing the reaction of formation in the matrix,whereby a more or less porous and bubbly mass resulted, or by moldingthe substances in a plastic incomplete'state and subsequently treatingthe article with formald'eyhde gas or liquid solution to harden thesame. In both cases, the resulting product was not suitable for soundrecords because of air'or gas bubbles and imperfections of surface whichcaused foreign noises when the record thus formed was reproduced, andotherwise impaired the quality of'the sound record. In the presentinvention these defects are eliminated, and a sound record maybeproduced which is most refractory to the wearing action of thereproducing stylus, and which is not deteriorated by the effects ofheat, moisture, handling and the action of the atmosphere thereon.

The invention may be practised in a number of ways. Attention is herebydirected to the accompanying drawings, forming part of thisspecification, and representing apparatzus in which my process may becarried on Figure 1 is an elevation, partly in section, of a suitablerotatable mold in which a cylindrical "sound record may be formed in thecase in which the formaldehyde or equivalent agent is used in the liquidsolution, and Fig. 2 is a similar view of apparatus adapted to the useof the formaldehyde or equivalent agent in the form of gas.

In carrying out the invention the ingredients such as albumenoids,caseins, gelatins,

phenols and their polymers, etc, together wlth an aldehyde, such asformaldehyde or equ valent agent containing the methylene radical CH maybe mixed together with a suitable condensing or catalytic agent andallowed to react with the application of heat to form a liquid-orplastic mass, which is then introduced into a matrix such as that shownin Fig. 1, in which the final reaction by which the non-plastic finalprodnet is formed, is caused to ensue, with application of heat, whilethe record is being molded. Or secondly, the body which it is intendedto use as the basis of the substance, such as gelatin or casein mass,may be rendered plastic by water and heat, and then introduced into thematrix, or a body which is already plastic, as phenol, may be used, andthe formaldehyde or equivalent agent with or without a catalytic orcondensing agent may be subsequently introduced, either in fluid, thatis, liquid or gaseous,

form, into thematrix, and the matrix and its contents heated to hastenthe completion of the condensation reaction and the equivalentpolymerization or other hardening process, which results in theformation of the final non-plastic product. Or thirdly, a

substance in liquid or plastic state may be introduced into the matrixtogether with a catalytic or other condensing agent, the substance sointroduced being of such a character that polymerization or equivalenthardening action of the substance to a non,- plastic permanent statewill be induced in the matrix by heat. As an example of the lastmentioned process, a condensation product of phenol with an aldehyde orother methylene-containing substance may be formed by mixing a phenol,as the well known phenol, carbolic acid, C,,H,OH, with an aldehyde, asformaldehyde, cH O, in equal molecular proportions and combined by heatand pressure, without the addition, however, of a catalytic orcondensing agent. The product thus obtained should, to obtain the bestresults,'be evaporated to remove excess of formaldehyde and water at atemp rature not exceeding 280 degrees F., and the product obtained issoluble and plastic or may be rendered plastic by heat, and this iscombined with a condensing or catalytic agent and a small quantity ofpolymerized aldehyde or other methylene-containing substance, such asparaform aldehyde, both preferably 111 anhydrous cond1t1on, and

' properly mixed, Such a condensing agent may be either an acid or abasic substance. I prefer, however, to use small quantities of acidradicals or substances which will readily yield a free acid radical,such as pinene hydrochlorid, sublimed aluminium chlorid, stannicchlorld, etc, because of their rapid action. This condensing agent maybe added to the mass at a relatively low temperature as by dissolvingthe mass in a volatile solvent in cases where the mass does not fuse atlow enough temperature, and then adding the condensing agent andparaform aldehyde, whereupon the product may be poured into the matrixand subjected to subsequent heat treatment while the record is beingformed.

In the first and third methods referred to above, a preliminaryreact-ion is caused between the diiferent ingredients before the sameare introduced into the mold, the final reaction only taking place inthe mold during the formation of the record by the molding process,whereas in the second of the three methods mentioned, the entirereaction between the ingredients takes place in the mold during theformation of the record. In all of these specific methods the finalproduct is formed in situ in the mold in which the record or otherobject cast is formed by a centrifugal action, the process used beingthat commonly known as spinning. By this method the deleterious effectsdue to porosity because of the setting or hardening or changing from theplastic to the non-plastic state while the mass is evolving gases, isprevented by the pressure exerted on the mass by the centrifugal actioninduced by the relatively high speeds at which the matrix is rotated.The force in,- aluced by this centrifugal action counteracts the tensionof dissociation in the mass being molded "so that the formation of gasis prevented or retarded and minimized attire cause of the high speedswhich may readily I be secured by this method. The spindle 3' may berotated by means of the belt wheel 7 secured to the spindle 3, overwhich a belt driven from any convenient source of power is adapted to beplaced, or the spindle 3 may be rotated by an individual drive, as bythe direct connection of some prime mover thereto, as is disclosed inapplication of Aylsworth and Aiken No. 495,301, filed May 11, 1909, uponwhich Patent No. 1,041,948 has been granted. In the case in which theformaldehyde or other aldehyde or methylene-containing substanceemployed is introduced in a liquid solution, the apparatus shown in Fig.1 may be used. Here, the material of an amount sufficient to form therecord is introduced'within the mold l and the cap 8 secured upon thecontainer2. The record 9 is then formed upon the bore of the mold 1 bycentrifugal action, the spindle 3 being rotated at a high speed. Duringthe formation of the record, the container 2, the mold 1 and the record9 in process of forming, are kept heated by any convenient means, as theburners 10. During this operation the final reaction between theingredients of the composition ensues, changing the same into anon-plastic body, which, as in the case of the resinized phenolcondensation products, may also be insoluble in all. ordinary solventsexcept boiling concentrated. sulphuric acid, and also infusible. Lesstime is consumed in the molding operation with the use of hightemperatures during the final reaction, and also the greater will be thetendency to the evolution of gases, necessitating an increase ofpressure to counteract the same as the temperatures are raised to lessenthe time factor.

Good results are obtained with the use of v that shown'in Fig. 2, inwhich thecap 8 is formed with a passageway'l-l'for the gas in,

the boss 12, andiwith a valve 13 for" closing the same. The bosslQmaylee-formed with a ccmnterweag? ,ed portion 14 to counter-' balance thevalve 13 during the rotation of the same. e

As stated, excellent results have been obtained in my process with theuse of both acid and basic substances as condensing agents. Smallpercentages of such substances as sodium hydroxid, lithium hydroxid,metallic oxids, and acid radicals may be used successfully.

When gelatins or other albu'menoids are used, the substance may besoaked in cold water until it swells, when the excess of Water isremoved. The swelled gelatin is then heated until it melts and is pouredhot into the mold and the aldehyde or methylene-containing substanceadded. In the case of formaldehyde solution, the proportions of thelatter may be varied between five and twenty per cent. of solution offormaldehyde. The temperature of the mold is maintained in the case ofsuch ingredients at about 212 degrees F. during the hardening operation.

During the various reactions of the ingredients in the processesdescribed, water is evolved and the reaction may be hastened in the caseof the closed mold by absorbing the water vapors as they are given off.This may be done by connecting the mold with a suitable chamber in whicha water absorbing substance is contained. Such substances as quick lime,zinc chlorid, phosphoric anhydrids or anhydrous copper sulfates may beused for this purpose.

In the case of the third specific method of combining the ingredientsdescribed above, the condensing agent may be added to a solutioncontuining the initial or intermediate reaction product of theingredients,

which has been formed without the aid of a catalytic agent, or thisintermediate product may be placed directly in the mold without the aidof a solution and the condenslng agent'added to the melted substance inthe mold. Where the condensing agent is added to the ingredientsdissolved in a volatile solvent as described, I have found good resultsto accrue'from also adding more aldehyde to the solution, preferably inthe form of paraform aldehyde or other solid alde-,

hyde. I have found excellent results to accrue from the use ofhydrochloric acid vapor or gas as a cataltic agent.

The present invention relates specifically to the novel method ofproducing pressure by which the dissociation gases which tend to beformed during the reaction are countel-acted. The pressure caused by thecentrifugal force due to the rotation of the' 'sufiicient quantity usedin the process.

(as can sound records. It is, however, obvious that it is alsoapplicable to the formation of other symmetrical objects of suchmaterials in which it is desirable that the vaporization of the masswhich would otherwise ensue during the reaction should be counteracted.Also, the method may be used inthe formation of disk sound records bythe use of a rotating mold such as that described and claimed in myapplication No. 493,052, filed April 29, 1909, in which the molds forthe disk records are secured to the sides of an eight-sided or otherpoly-sided chamber, which is rotated about its axis, throwing the liquidor plastic material into thev various molds, the material being measuredand only if course, it is also obvious that other objects besides disksoundrecords might easily be manufactured in the same manner.

Having now described my invention, what I'claim and desire to protect byLetters Patcm is as follows 1. The method of molding sound records andother objects of substances non-plastic in their final condition,consisting in heating in a revoluble mold a fluid mass comprising amethylene containing substance and a substance which reacts with saidmethylene containing substance upon application of heat or mold, and atthe same time revolving the mold at a high rate of. speed to spread themass uniformlyover the mold surface and. also to counteract the tensionof dissociation in the massduring its reaction, and continuing theoperation untilthe final non-plastic cast is formed, substantially asdescribed.

2. The method of molding sound records and other objects of substancesnon-plastic in their final condition, consisting in introducing into asuitable rotatable mold a sub stance which reacts with formaldehyde onapplication of heat to form a substance which in its final stage isnon-plastic at such temperatures as may be employed without injury tothe substance or mold, and a suflicient amount of fluid formaldehyde tocause the reaction. applying heat, causing the final reaction betweenthe ingredients to ensue in the mold, and at the same time revolving themold at a high rate of speed to spread the substance uniformly over themold surface,

and also to counteract the tension of disso-- ciation in the substanceduring its reaction, and continuing the operation until the finalnon-plastic cast is formed, substantially as described. i

3. The method of molding sound records and other objects of substancesnon-plasticin their final condition, consisting in introducing into asuitable rotatable mold a substance which reacts with a substance con.-

taining the methylene radical'upon application of heat to form asubstance which in its final stage is non;plastic at such tempera turesas may be employed Without injuryto the substance or mold, and asuilicient amount of fluid methylene-containing substanceto cause thereaction, applying heat, causing the final reaction between theingredients to ensue in the mold ,and at the same time revolving themold at a high rate of speed to spread the substance uniformly over themold surface and also to counteract the tension of dissociation in thesubstance during its reaction, and continuing the oper ation until thefinal non-plastic cast is formed, substantially as described.

4-. The method of molding sound records and other objects of substancesnon-plastic in their final condition, consisting in rendering plasticand introducing within a suitable rotatable mold a substance whichreacts with an aldehyde on application of heat to form a substance whichin its final stage is noneplastic at such temperatures as may beemployed without injury to the sub stance or mold, introducing into themold and substance a sufiicient amount of a fluid. aldehyde ;to causethe reaction, applying heat sufficient to cause the entire reaction toensue in the mold and at thesame time revolving the mold at a high rateof speed to spread the substance uniformly over the mold surface, andalso to counteract the tension of dissociation in the substance duringits reaction by centrifugal force, and continuing the operation untilthe final nonplastic cast is formed, substantially as described.

5. The method of molding sound'records and other objects of substancesnon-plastic in their final condition, consisting in rendering plasticand introducing within a suitable rotatable mold a substance whichreacts with a methylene-containing substance on application of heat toform a substance which in its final stage is non-plastic at suchtemperatures as may be employed Without injury to the substance or mold,,introducing into the mold and substance a s'uflicient amount of a fluidmethylene-containing substance to cause the reaction, applying heatsufficient to cause the entire reaction to ensue in the mold. and at thesame time revolving the mold at a high rate of speed to spread thesubstance uniformly over the mold surface and also .to counteract thetension of dissociation in the substance during its reaction bycentrifugal force, and continuing the operation until the finalnon-plastic cast is formed, substantially as described.

6. The method of molding sound. records and other objects of substancesnon-plastic in their final condition, consisting in rendering plasticand introducing Within a suitable rotatable mold a substance whichreacts with an aldehyde on application of heat to form a substance whichin its final stage is non-plastic at such temperatures as may beemployed without injury to the substance or mold, introducing into themold and substance a sufficient amount of a fluid aldehyde andacondensing agent to cause the reaction, applying heat suflicient tocause the entire reaction to ensue in the mold and at the same timerevolving the mold at a high rate of speed to spread the substanceuniformly over the moldsurface, and also to counteract the tension ofdissociation in the substance during its reaction by centrifugal force,and continuing the operation until the final non plastic cast is formed,substantially as described.

7. The method of molding sound records and other objects of substancesnon-plastic in their final condition, consisting in applying heat to aphenol, formaldehyde, and a condensing agent in a suitable rotatablemold sufiicient to cause a reaction to-trans form the substances into ahard non-plastic substance and at the same time revolving the mold at ahigh rate of speed to spread the substance uniformly over the moldsurface, and also to counteract the tension of dissociation in thesubstance during its reaction by centrifugal force,and continuing theoperation until the final non-plastic cast is formed, substantially asdescribed.

This specification signed and witnessed this 28th day of April 1909.

JONAS W. AYLSWORTH. Witnesses:

- DYER SMITH,

'JOIIN M. CANFIELD.

